Content

General information

• General repair instructions
• Notes on the format of this manual
• Identification
• Lifting instructions
• Conversion table

Maintenance and lubrication

• Maintenance schedule
• Severe conditions maintenance schedule
• Recommended fluids and lubricants
• Oil viscosity chart

Heating and ventilation

• General description
• Main data and specifications
• Special parts fixing nuts and bolts
• On-vehicle service
• Condenser
• Condenser fan motor
• Receiver / drier
• Compressor
• Heater unit
• Vent unit
• Evaporator
• Duct
• Blower unit
• Defroster nozzle and vent duct
• Rear heater duct
• Control lever
• Control panel illumination bulb
• Troubleshooting
• Special service tool

Frame and bumper

• Front bumper
• Rear step bumper
• Rear bumper and rear guard
• Front air dam
• Frame dimensions
• Sheet metal
• Front alignment

Power assited steering system

• General description
• Power steering system test
• Maintenance
• Fluid level
• Bleeding the power steering system
• Bleeding procedure
• Flushing the power steering system
• Steering wheel free play inspection
• Front end alignment inspection and adjustment
• Special tools
• Power steering unit
• Power steering pump
• Supplemental restraint system steering wheel and column
• Inflator module
• Steering wheel
• The adjustment method in case a mark has not been applied
• Combination switch
• Lock cylinder
• Steering column
• Supplemental restraint system steering wheel and column and associated parts

Front suspension

• Main data and specifications
• Torque specififcations
• Front suspension

Rear suspension

• Main data and specifications
• Rear suspension
• Leaf spring and shock absorber
• Leaf spring assembly
• Rear stabilizer bar
• Troubleshooting

Wheels and tires

• Main data and specifications
• Torque specifications
• Wheels and tires
• Troubleshooting

Propeller shaft

• Service precaution
• Main data and specifications
• Rear propeller shaft
• Front propeller shaft

Rear axle

• Main data and specifications
• Recommended liquid gasket
• Recommended thread locking agents
• Rear axle assembly Servicing
• Rear axle
• Differential
• Differential cage
• Limited slip differential

Front wheel drive

• Main data and specifications
• Special parts fixing nuts and bolts
• Recommended liquid gasket
• Recommended thread locking agents
• Servicing
• General description
• Front drive axle
• Front axle drive shaft
• Differential
• Front hub and disc
• Troubleshooting
• Special service tool

Shift on the fly system

Brake control system

• Service precaution
• General description
• General diagnosis

Anti-lock brake system

• Service precaution
• Torque specifications
• Electronic hydraulic control unit
• Front wheel speed sensor
• Rear wheel speed sensor
• Front sensor rotor
• Rear sensor rotor
• G-sensor
• Special tools

Brakes

• General description
• Main data and specifications
• Torque specifications
• Servicing
• Front disc brake
• Rear drum brake
• Brake control
• Master cylinder
• Vacuum booster
• Special tools

Parking brake system

• Service precaution
• Parking brake lever
• Front parking brake cable
• Parking brake lever
• Parking brake rear cable
• Main data and specifications

Engine mechanical

• Main data and specifications
• Torque specifications
• Recommended liquid gasket
• Loctite application procedure
• Servicing
• General description
• Removal and installation
• Engine repair kit
• Engine overhaul
• Inspection and repair
• Reassembly
• Installation
• Lubrication system
• Lubricating flow
• Oil pump and oil filter
• Oil pump
• Oil filter and oil cooler
• Inter cooler
• Special tools

Engine cooling

• Main data and specifications
• Diagnosis
• Draining and refilling cooling system
• Water pump
• Thermostat
• Radiator
• Fan clutch with cooling fan

Fuel system

• Main data and specifications
• General description
• Fuel tank
• Fuel gauge unit
• Fuel tube / quick - connector fittings
• Filler neck
• Fuel filler cap
• Injection pump
• Injection nozzle
• Special tools

Engine electrical

• Main data and specifications
• General description
• Torque specifications
• Generator
• Starter motor
• Pre-heating system

Engine control system

Exhaust system

• Main data and specifications
• General description
• Removal and installation
• Inspection and repair
• General description
• Egr system diagram.
• Egr cooler
• Turbocharger
• Special tools
• Ihi service network

Accelerator control

Ignition system

• General description
• Service precaution
• Diagnosis
• Ignition coil
• Spark plug
• Crankshaft angle sensor
• Main data and specifications

Starting and charging system

• Starting system
• General description
• Service precaution
• Diagnosis
• Starter
• Charging system
• Generator
• Technical data

Engine driveability and emissions

Induction

• Service precaution
• Air cleaner filter

Transmission

• Automatic transmission 4l60E
• Transmission AW30-40LE model
• Transmission JR405E model
• Manual transmission msg mua mux models
• Clutch
• Transfer case

Electrical-body and chassis

• General information
• Notes for working on electrical items
• Symbols and abbreviations
• Parts for electrical circuit
• Wiring
• Fuse
• Fusible link
• Relay
• Diode
• Connector
• Battery
• Reading the circuit diagram
• Parts location
• Circuit diagram
• Connector list
• Main data and specifications
• Bulb specifications
• Relay and fuse
• Relay and fuse box location
• Relay location
• Fuse and slow blow fuse location
• Diode location
• Fuse block circuit
• Grounding point
• Cable harness routing
• System repair
• Connector list

Cruise control system

• General description
• Brake switch
• Clutch switch
• Starter switch
• Cruise control main switch

Accessories

• Parts location
• Circuit diagram
• Connector list
• Audio
• Front speaker
• Tweeter
• Rear speaker
• Clock
• Antenna

Supplemental restraint system

• Service precaution
• General description
• Circuit diagram
• SRS component and wiring location view
• Component description
• Definitions
• Diagnosis
• SRS connector body face views
• Repairs and inspections required after an accident
• On-vehicle service
• Air bag assembly handling / shipping / scrapping
• Air bag assembly shipping procedure for live (undeployed) air bag
• Service precautions for SRS component service
• SRS connectors
• SRS control unit
• Driver air bag assembly
• Steering wheel
• SRS coil assembly
• Steering column
• Passenger air bag
• Pretensioner seat belt
• Main data and specifications
• Special tools

Restraint control system

• Service precaution
• Diagnosis information
• Diagnostic procedures
• Diagnostic codes
• How to read trouble codes
• How to clear trouble codes
• Scan tool diagnostics
• Basic knowledge required
• Basic electrical circuits
• "Flash code" diagnostics
• Data list
• Diagnostic trouble codes
• System schematic
• SRS diagnostic system check

Cab

• Windshield
• Rear window
• Front door
• Rear door
• Instrument panel
• Floor console
• Console box
• Headlining
• Interior trim panels
• Fuel filler lid opener lever / cable
• Quarter glass
• Front seat
• Rear seat
• Jump seat
• Front seat belt
• Rear seat belt
• Front wheel extension
• Rear wheel extension
• Tail gate

Security

• Immobilizer control system
• Immobilizer system
• Antitheft system